US8784671B2 - Method of manufacturing a press plate, a press plate, a method of embossing a floor panel, and a floor panel - Google Patents

Method of manufacturing a press plate, a press plate, a method of embossing a floor panel, and a floor panel Download PDF

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Publication number
US8784671B2
US8784671B2 US12/681,220 US68122008A US8784671B2 US 8784671 B2 US8784671 B2 US 8784671B2 US 68122008 A US68122008 A US 68122008A US 8784671 B2 US8784671 B2 US 8784671B2
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Prior art keywords
press plate
surface treatment
fine projections
resistant material
plate surface
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US20100260969A1 (en
Inventor
Bruno Vermeulen
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Unilin BV
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Spanolux NV SA
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Assigned to UNILIN BVBA reassignment UNILIN BVBA CORRECTIVE ASSIGNMENT TO CORRECT THE RECEIVING PARTY STATE/COUNTRY PREVIOUSLY RECORDED ON REEL 042328 FRAME 0096. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Assignors: SPANOLUX N.V.-DIV. BALTERIO
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Assigned to FLOORING INDUSTRIES LIMITED, SARL reassignment FLOORING INDUSTRIES LIMITED, SARL CORRECTIVE ASSIGNMENT TO CORRECT THE ADDRESS OF ASSIGNEE PREVIOUSLY RECORDED ON REEL 056494 FRAME 0304. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Assignors: UNILIN, BV
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/02—Designs imitating natural patterns wood grain effects
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Definitions

  • aspects of the present invention relate to a method of manufacturing a press plate for applying a surface structure onto a floor panel, wherein the press plate includes a press plate surface.
  • WO 2006/063803 discloses a press plate which has been provided with zones having different degrees of gloss so as to enable manufacturing of floor panels having zones with different degrees of gloss.
  • a wood pattern may be imitated.
  • An aspect of the present invention aims to provide a method of manufacturing a press plate which, when used in a method of manufacturing floor panels, provides the opportunity to improve the natural appearance of floor panels.
  • first fine projections are created on the press plate surface, then the resulting fine projections are covered by a surface treatment resistant material, and subsequently the press plate surface including the resistant material is submitted to a surface treatment.
  • the fine projections on the press plate surface may be elongated projections having a width of less than 1 mm, for example.
  • the press plate When the press plate is used for applying a surface structure onto a floor panel, the floor panel will obtain depressed portions imitating natural materials, such as pores in wood. This means that the fine projections may have a great variety of shapes.
  • the depressed portions of the floor panels When using conventional press plates the depressed portions of the floor panels have a similar or lower gloss level than the surrounding panel surface. Due to the present method, floor panels can be manufactured such that those comprise nerves or pores having a higher gloss level than the surrounding panel surface.
  • the surface treatment may be a chemical surface treatment, for example an etching treatment, but other (chemical) surface treatments are conceivable.
  • An alternative surface treatment may be sand blasting.
  • the manufacturing method may be performed in several etching steps.
  • the fine projections may be created on the press plate surface by etching the press plate surface adjacent to the intended locations of the fine projections. This means that before a first etching step the press plate surface may be a flat surface, which is provided with etching-resistant material. After the first etching step the fine projections may be formed. At this stage the fine projections may have a surface structure including a limited roughness.
  • the etching-resistant material is printed onto the fine projections by a digitally controlled printer.
  • the accuracy of conventional techniques, such as that of a silk screen process appear to be insufficient for providing the etching-resistant material onto the fine projections.
  • a chrome treatment may be performed in order to increase the hardness of the surface structure.
  • An aspect of the invention also relates to a press plate for applying a surface structure onto a floor panel, wherein the press plate includes a press plate surface provided with fine projections, wherein the surface structure of the fine projections has a degree of smoothness which is higher than that of the press plate surface adjacent to the projections so as to create a lower level of roughness of the press plate surface at the fine projections.
  • An aspect of the invention also relates to a method of embossing a floor panel by using the above-mentioned press plate.
  • An aspect of the invention also relates to a floor panel including an upper side, provided with a decoration layer having a surface structure pattern imitating a natural material, such as a wood pattern, wherein the surface structure pattern includes depressed portions, wherein the depressed portions have a different surface structure roughness with respect to the remaining portion of the upper surface.
  • FIG. 1 is a schematic plan view of a portion of an embodiment of the press plate on a large scale according to the invention.
  • FIG. 2 is a cross-sectional view along the line II-II in FIG. 1 .
  • FIG. 3 a - h are illustrative views, showing subsequent steps of an embodiment of the method according to the invention.
  • FIG. 1 shows a plan view of a portion of an embodiment of a press plate 1 , which in general is made of steel.
  • the press plate 1 includes a press plate surface 2 and is provided with fine projections 3 .
  • These fine projections 3 may be made by removing surface material from the press plate surface 2 , which initially may be a flat surface, adjacent to the locations where the fine projections 3 are intended. This can be achieved by etching, for example.
  • the press plate 1 When manufacturing floor panels the press plate 1 is pressed onto an upper surface of the floor panel such that depressed portions arise in the upper surface of the panel. In the case of a desired wood pattern the depressed portions may imitate nerves or pores of natural wood.
  • a further improvement of natural wood imitation is achieved by adapting the upper surface of the panel such that in the nerves or pores the gloss degree is higher than at the remaining portion of the upper surface. This can be achieved by making the surface structure of the upper surface of the floor panel within the nerves or pores smoother than in the remaining portion of the upper surface.
  • the surface structure of the fine projections 3 on the press plate 1 has a degree of smoothness which is higher than that of the press plate surface 2 adjacent to the fine projections 3 . This is illustrated in FIGS. 1 and 2 by the rough regions 4 .
  • Such a press plate 1 can be manufactured by first creating the fine projections 3 on the press plate surface 2 , then covering the resulting fine projections 3 by an etching-resistant material, and subsequently etching the press plate surface 2 .
  • the etching-resistant material can be printed onto the fine projections by a digitally controlled printer, because this can accurately print the material on the fine projections 3 .
  • After etching the etching-resistant material can be removed from the press plate surface 2 .
  • the fine projections 3 have a different surface structure roughness than the press plate surface 2 adjacent to the fine projections 3 .
  • FIG. 3 a shows a steel plate 1 having a flat press plate surface 2 .
  • Etching-resistant material 5 is applied onto the press plate surface 2 , see FIG. 3 b .
  • the press plate surface 2 is submitted to an etching treatment, resulting in a surface 2 including fine projections 3 as shown in FIG. 3 c .
  • FIG. 3 d shows the condition after removing the etching-resistant material 5 .
  • the press plate surface 2 is provided with a chrome layer 6 for gloss control, see FIG. 3 e . In this condition the entire press plate surface 2 has the same gloss level.
  • FIG. 3 g illustrates a sand blasting treatment as a surface treatment of the press plate surface 2 .
  • the surface treatment resistant material 7 is not or only partly removed by sand blasting.
  • the press plate surface 2 includes fine projections 3 having a low surface roughness (A) and surrounding portions having a high roughness (B), see FIG. 3 h .
  • the step of sand blasting may be replaced by a chemical surface treatment such as etching, wherein the surface treatment resistant material comprises an etching resistant material.
  • the invention provides a method of manufacturing a press plate, wherein the resulting press plate provides the opportunity to improve the natural appearance of floor panels.
  • the press plate may be a roller instead of a flat plate.
  • the press plate is not only suitable for applying patterns of wood on floor panel, but also for other natural materials such as stone and the like.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
  • Printing Plates And Materials Therefor (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
US12/681,220 2007-10-05 2008-10-02 Method of manufacturing a press plate, a press plate, a method of embossing a floor panel, and a floor panel Active 2029-09-14 US8784671B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP07117972A EP2045363B1 (en) 2007-10-05 2007-10-05 A method of manufacturing a press plate and a method of embossing a floor panel
EP07117972.5 2007-10-05
EP07117972 2007-10-05
PCT/EP2008/063249 WO2009043910A1 (en) 2007-10-05 2008-10-02 A method of manufacturing a press plate, a press plate, a method of embossing a floor panel, and a floor planel

Publications (2)

Publication Number Publication Date
US20100260969A1 US20100260969A1 (en) 2010-10-14
US8784671B2 true US8784671B2 (en) 2014-07-22

Family

ID=38983367

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US12/681,220 Active 2029-09-14 US8784671B2 (en) 2007-10-05 2008-10-02 Method of manufacturing a press plate, a press plate, a method of embossing a floor panel, and a floor panel

Country Status (10)

Country Link
US (1) US8784671B2 (pl)
EP (2) EP2045363B1 (pl)
CN (1) CN101889106B (pl)
AT (1) ATE537008T1 (pl)
CA (1) CA2701681C (pl)
DE (1) DE202007019084U1 (pl)
DK (1) DK2045363T3 (pl)
PL (2) PL2045363T3 (pl)
RU (1) RU2490373C2 (pl)
WO (1) WO2009043910A1 (pl)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150343835A1 (en) * 2011-03-10 2015-12-03 Hueck Rheinische Gmbh Method for Processing a Structured Surface of an Embossing Tool
US10563309B1 (en) 2015-10-13 2020-02-18 Kings Mountain International, Inc. Method for creating a textured press plate
DE102022116429A1 (de) 2022-06-30 2024-01-04 Hueck Rheinische Gmbh Verfahren zur Bearbeitung einer Oberfläche eines Presswerkzeugs und Polierwerkzeug zum Polieren einer Oberfläche eines Presswerkzeugs

Families Citing this family (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE1018156A3 (nl) * 2008-05-20 2010-06-01 Flooring Ind Ltd Sarl Werkwijze voor het vervaardigen van beklede panelen en bekleed paneel.
US8051886B2 (en) 2009-12-14 2011-11-08 Unilin Flooring Nc Llc Distressing process and apparatus for applying such process
DK2363299T3 (da) * 2010-03-05 2013-01-28 Spanolux N V Div Balterio Fremgangsmåde til fremstilling af en gulvplade
CN102689335B (zh) * 2011-03-21 2015-09-16 圣象（江苏）木业研究有限公司 高、低光相间饰面的人造板制造方法及制造模板
DE102012005312A1 (de) * 2012-03-19 2013-09-19 Nora Systems Gmbh Bodenbelag
DE202012004375U1 (de) * 2012-05-04 2012-06-11 Hueck Rheinische Gmbh Werkstoffplatte mit einer strukturierten Oberfläche
DE102012107526A1 (de) * 2012-08-16 2014-05-22 Sandvik Surface Solutions Division Of Sandvik Materials Technology Deutschland Gmbh Oberflächenstrukturierung von Presswerkzeugen
CN103264433B (zh) * 2013-05-24 2015-05-20 广东萨米特陶瓷有限公司 制作瓷质仿石图案制品的预先挤压制形装置及其使用方法
BE1026771B1 (nl) 2018-11-09 2020-06-15 Unilin Bvba Bekleed paneel en werkwijze voor het vervaardigen van beklede panelen.
BE1026995B1 (nl) 2018-11-09 2020-08-27 Unilin Bvba Bekleed paneel en werkwijze voor het vervaardigen van beklede panelen
WO2020095196A1 (en) 2018-11-09 2020-05-14 Unilin, Bvba Covered panel and method for manufacturing covered panels
DE102022116428A1 (de) 2022-06-30 2024-01-04 Hueck Rheinische Gmbh Verfahren zur Bearbeitung einer Oberfläche eines Presswerkzeugs, sowie Vorrichtung zur Bearbeitung einer Oberfläche eines Presswerkzeugs

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Publication number Priority date Publication date Assignee Title
US3668030A (en) * 1970-09-08 1972-06-06 Frank W Broderick Method of making mating male embossing rolls
GB2054458A (en) 1979-07-02 1981-02-18 Toppan Printing Co Ltd A decorative laminate and a manufacturing method therefor
DE3120351C1 (de) 1981-05-22 1982-12-09 Standex International Gmbh, 4150 Krefeld Verfahren zur Herstellung einer Prägegravur auf einem der Oberflächenformung von Preßlaminaten dienenden Prägewerkzeug
EP0256803A2 (en) 1986-08-07 1988-02-24 Praxair S.T. Technology, Inc. Embossing tools, their formation and use
US5298116A (en) * 1991-04-29 1994-03-29 Standex International Engraving Gmbh Process for producing a matted embossing surface for an embossing tool for making press-formed laminates
JPH0872141A (ja) 1994-09-06 1996-03-19 Dainippon Printing Co Ltd エンボス版の製造方法
US5753722A (en) * 1995-12-13 1998-05-19 Taiyo Ink Manufacturing Co., Ltd. Photocurable and thermosetting matte liquid resist composition
US6129800A (en) * 1994-12-12 2000-10-10 K2, Inc. Process for preparing embossed metal foil laminate
US20030102284A1 (en) * 2000-01-31 2003-06-05 Walter Schmidt Method for fabricating micro-structures with various surface properties in multi-layer body by plasma etching
WO2006063803A2 (en) 2004-12-16 2006-06-22 Flooring Industries Ltd Floor panel imitating a wood pattern on its surface and method for manufacturing
US20070068898A1 (en) * 2005-09-29 2007-03-29 Lorenz Glen D Multi-level etching method and product
US20080248206A1 (en) * 2004-05-05 2008-10-09 Perini Engraving S.R.1. Via Per Mugnano, 815 Embossing Rollers with Surface Treatment, Method for the Production Thereof and Embossing Unit Comprising said Rollers

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DE3211388C1 (de) 1982-03-27 1983-06-01 Fa. Eduard Hueck, 5880 Lüdenscheid Verfahren zur Herstellung von strukturierten Oberflächen auf Blechen, Walzen oder Endlosbändern aus Stahl oder Nichteisenmetallen
SU1429085A1 (ru) * 1986-04-08 1988-10-07 Организация П/Я Р-6007 Способ изготовлени пресс-формы дл отражател жидкокристаллического диспле
DE10217919B4 (de) 2002-04-23 2005-07-21 Hw-Industries Gmbh & Co. Kg Verfahren zur Herstellung von Laminat-Paneelen

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3668030A (en) * 1970-09-08 1972-06-06 Frank W Broderick Method of making mating male embossing rolls
GB2054458A (en) 1979-07-02 1981-02-18 Toppan Printing Co Ltd A decorative laminate and a manufacturing method therefor
DE3120351C1 (de) 1981-05-22 1982-12-09 Standex International Gmbh, 4150 Krefeld Verfahren zur Herstellung einer Prägegravur auf einem der Oberflächenformung von Preßlaminaten dienenden Prägewerkzeug
EP0256803A2 (en) 1986-08-07 1988-02-24 Praxair S.T. Technology, Inc. Embossing tools, their formation and use
US4787837A (en) 1986-08-07 1988-11-29 Union Carbide Corporation Wear-resistant ceramic, cermet or metallic embossing surfaces, methods for producing same, methods of embossing articles by same and novel embossed articles
US5298116A (en) * 1991-04-29 1994-03-29 Standex International Engraving Gmbh Process for producing a matted embossing surface for an embossing tool for making press-formed laminates
JPH0872141A (ja) 1994-09-06 1996-03-19 Dainippon Printing Co Ltd エンボス版の製造方法
US6129800A (en) * 1994-12-12 2000-10-10 K2, Inc. Process for preparing embossed metal foil laminate
US5753722A (en) * 1995-12-13 1998-05-19 Taiyo Ink Manufacturing Co., Ltd. Photocurable and thermosetting matte liquid resist composition
US20030102284A1 (en) * 2000-01-31 2003-06-05 Walter Schmidt Method for fabricating micro-structures with various surface properties in multi-layer body by plasma etching
US20080248206A1 (en) * 2004-05-05 2008-10-09 Perini Engraving S.R.1. Via Per Mugnano, 815 Embossing Rollers with Surface Treatment, Method for the Production Thereof and Embossing Unit Comprising said Rollers
WO2006063803A2 (en) 2004-12-16 2006-06-22 Flooring Industries Ltd Floor panel imitating a wood pattern on its surface and method for manufacturing
US20070068898A1 (en) * 2005-09-29 2007-03-29 Lorenz Glen D Multi-level etching method and product

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150343835A1 (en) * 2011-03-10 2015-12-03 Hueck Rheinische Gmbh Method for Processing a Structured Surface of an Embossing Tool
US9561524B2 (en) * 2011-03-10 2017-02-07 Hueck Rheinische Gmbh Method for processing a structured surface of an embossing tool
US10563309B1 (en) 2015-10-13 2020-02-18 Kings Mountain International, Inc. Method for creating a textured press plate
DE102022116429A1 (de) 2022-06-30 2024-01-04 Hueck Rheinische Gmbh Verfahren zur Bearbeitung einer Oberfläche eines Presswerkzeugs und Polierwerkzeug zum Polieren einer Oberfläche eines Presswerkzeugs

Also Published As

Publication number Publication date
WO2009043910A1 (en) 2009-04-09
DE202007019084U1 (de) 2010-08-19
CN101889106B (zh) 2012-12-26
EP2045363B1 (en) 2011-12-14
CA2701681C (en) 2016-09-13
RU2010114661A (ru) 2011-11-10
DK2045363T3 (da) 2012-04-02
US20100260969A1 (en) 2010-10-14
CA2701681A1 (en) 2009-04-09
PL2045363T3 (pl) 2012-05-31
EP2220269A1 (en) 2010-08-25
EP2220269B1 (en) 2017-12-06
EP2045363A1 (en) 2009-04-08
PL2220269T3 (pl) 2018-07-31
ATE537008T1 (de) 2011-12-15
RU2490373C2 (ru) 2013-08-20
CN101889106A (zh) 2010-11-17

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